Toe protector

ABSTRACT

A shoe insert is configured to receive a foot of a wearer. According to various implementations, the shoe insert includes an inner piece and an outer piece. The outer piece covers the inner piece. The inner piece includes dividers that at least partially separate toes of the foot and protects the toes from, for example, the impact of a heavy object.

TECHNICAL FIELD

The present disclosure relates generally to shoe inserts and, more particularly, to shoe inserts that protect a wearer's toes.

BACKGROUND

Playing contact sports such as basketball poses many hazards. One well-known hazard is the risk of foot injury. Injuries from twisting or over extension (e.g., ankle sprains, turf toe, Achilles tendonitis) are the most common types of sports-related foot injuries. Injuries resulting from an impact on the top of the foot, particularly on the toes, can be just as debilitating, however. This type of injury can also occur in an industrial work environment, such as when heavy boxes or other objects are accidentally dropped on a worker's foot.

DRAWINGS

The features of the present techniques may be best understood from the following detailed description taken in conjunction with the accompanying drawings of which:

FIG. 1 is a transparent perspective view of a shoe insert, according to an embodiment.

FIG. 2 is top view of outer piece of a shoe insert according to an embodiment (in an unfolded configuration).

FIG. 3 is top view of an outer piece of a shoe insert according to an embodiment (with a wearer's foot inserted, but without a shoe).

FIG. 4 is a side view of a shoe insert on a wearer's foot according to an embodiment (with a wearer's foot inserted, but without a shoe).

FIG. 5A is a front view of an inner piece of a shoe insert according to an embodiment.

FIG. 5B is a bottom view of an inner piece of a shoe insert according to an embodiment.

FIG. 5C is a side view of an inner piece of a shoe insert according to an embodiment.

DESCRIPTION

In various embodiments: A shoe insert (“insert”) provides protection (e.g., protection from the impact of a heavy weight) for the toes of a user (also referred to herein as a “wearer”). The insert compartmentalizes each toe like a glove and can be worn on top of or underneath socks. The insert distributes the impact of weight dropped onto the toes by spreading the force to other parts of the shoe's structure, thereby lowering the total force on the toes (by two thirds in some implementations). The insert may be produced in multiple sizes (e.g., small, medium, and large).

Turning to FIGS. 1-5C, a shoe insert according to an embodiment is shown. The shoe insert, generally labelled 10, is configured to be inserted into a shoe so that it protects a wearer's foot 11 when the wearer's foot 11 is inside the insert 10. The insert 10 includes an outer piece 12 and an inner piece 14. The outer piece 12 has first surface 13 and a second surface 15. The outer piece 12 is generally flat and includes one or more layers of material between the first surface 13 and the second surface 15. The outer piece 12 has a generally curvilinear quadrilateral shape with a concave edge 16, a convex edge 18, a left lateral side 20, and a right lateral side 22. On the left lateral side 20 are a left upper tab 24 and a left lower tab 26. On the right lateral side 22 are a right upper tab 28 and a right lower tab 30. The outer piece 12 also has a series of padded portions 32, which help protect the wearer's toes. Each padded portion 32 is thicker than an area of the outer piece 12 surrounding the padded portion 32, and at least some of the padded portions 32 is disposed on a location of the outer piece 12 that corresponds to a respective toe of the wearer. For example, one padded portion 32 sits above the big toe, another padded portion 32 is sits above the second portion 32, etc. Other padded portions 32 are disposed on the respective tabs 24, 26, 28, and 30.

As shown in FIG. 4, when the insert 10 is in use, the right lower tab 30 and the right upper tab 28 each partially cover a lateral right side 40 of the foot 11 and are positioned such that the right lower tab 30 is located closer to the end 42 of the foot 11. Similarly, though not depicted in FIG. 4, the left lower tab 26 and the left upper tab 24 each partially cover a lateral left side of the foot 11 and are positioned such that the right lower tab 30 is located closer to the end 42 of the foot 11.

Turning to FIG. 5A, FIG. 5B, and FIG. 5C, in an embodiment, the inner piece 14 includes a shield 50 and a series of dividers 52 extending from the shield 50. The dividers are configured so that, during use, when the inner piece 14 is positioned on top of the wearer's toes, the dividers 52 at least partially separate the wearer's toes. For example, one divider may be positioned between the wearer's first toe (“big toe”) and second toe, one divider may be positioned between the wearer's second toe and third toe, one divider may be positioned between the wearer's third toe and fourth toe, and one divider may be positioned between the wearer's fourth toe and fifth toe (“pinkie toe”). As the wearer engages in physical activity, the inner piece 14 houses and protect the toes, provides stability, and acts as both a cushion and as a splint to keep the toes stable.

According to an embodiment, the insert 10 is constructed so that the outer piece 12 folds back onto itself so that a first portion 13 a of the first surface 13 faces a second portion 13 b of the first surface 13 so that the outer piece 12 covers the inner piece 14.

In an embodiment, to use the insert 10, a wearer places the insert 10 into a shoe and then inserts a foot into the insert so that the wearer's toes are at least partially separated (e.g., at least one gap is created between each adjacent pair of toes by a divider). The wearer repeats this procedure with the other shoe. The outer piece 12 consequently covers the end of the wearer's foot in addition to covering the second piece 14.

According to an embodiment, the inner piece 14 is made of a medium stiffness silicone.

In an embodiment, one or both of the outer piece 12 and the inner piece 14 are made of a thermoplastic elastomer.

According to an embodiment, the insert 10 is made of two different types of plastics—a stiffer material for the inner piece 14 than for the outer piece 12. The two different pieces go through separate processes until their final shapes are manufactured. After that, they are joined (e.g., with an adhesive) to form a finished insert.

In an embodiment, the insert 10 is manufactured as follows. The material for the insert is shipped in from an external factory. The shipment may be silicone in a pellet state for the inner piece 14 and a foam type thermoplastic elastomer in pellet form for the outer piece 12. Once the pellets have been heated they become liquid. Each piece is then molded into its respective shape and taking to a settling station.

According to an embodiment, once both pieces are taken to the settling station they will be put in the joining area. The parts will be joined by an epoxy. The epoxy will then be allowed to dry and the insert will be taken to a packaging machine. The operator will place the finished insert inside of a thin plastic package with both sides open on it. The operator will then use the packaging machine by placing the ends inside the machine. Once in position the machine clamps down and seals both ends by heating them and compressing. The package itself will have a hole in it to allow air to flow through it to allow the epoxy to cure. After packaging, the insert will be taken to a storage area to be place in boxes and prepared for shipping.

Forming the Inner Piece 14

According to various embodiments, the first piece can be made by, for example, injection molding or compression molding.

Injection Molding

Injection molding is a type of molding in which the polymer is heated until it is in a highly plastic state and then forced, using high pressure, to flow into a mold cavity where it solidifies. The mold is then pulled apart leaving the cooled product. The process takes anywhere from ten seconds up to a minute. Because the inner piece 14 is smaller, it may take closer to 10 seconds to cool and solidify.

According to an embodiment, the material for the inner piece 14 is first placed into a feed hopper and then subsequently allowed to flow into an injection unit, where it is forced through a nozzle. A nonreturn valve keeps the material from flowing backwards in the machine. From the nozzle, the material is forced into a mold. The material is then allowed to cool and the mold (which is made of two separate pieces) is opened up, thereby allowing the piece to be removed.

In an embodiment, the mold used for the inner piece 14 is a two-plate mold. The two plate mold includes two halves that have a cavity in them in the shape of the inner piece 14. The mold may also include a cooling system that allows for water to flow through the mold but not come in contact with the inner piece 14, thereby allowing it to cool faster.

Compression Molding

Another type of forming process that can be used is compression molding. To carry out compression molding, the raw material (a “charge”) is placed into a mold. The charge itself can be in a liquid, powder, or pellet form and is inserted in a measured amount to make sure that the density and composition is constant. The mold is made of two halves—a lower half and an upper half. The upper half is lowered onto the lower half and compresses the material to take the shape of the cavity in the mold. The mold is then heated, allowing the charge to polymerize and then cure as it cools. Once cool, it will have the shape of the cavity. The mold will then be opened up the part removed.

Forming the Outer Piece 12

In an embodiment, the outer piece 12 is a thin walled hollow piece that takes the shape of the front half of a shoe. In various embodiments, the outer piece 12 is made by blow molding or by rotational molding.

Blow Molding

Blow molding works as follows: one starts with a tube of molten plastic known as a parison and the tube is inflated to fit the desired shape.

Rotational Molding

Rotational molding uses gravity to cause the material to take the form of the cavity. This process is also known as rotomolding. Rotomolding is used to form more complex external geometries and may be used to take the shape of a foot. To carry out this process, a predetermined amount of polymer powder is loaded into the cavity. The mold is then heated and rotated on two perpendicular axis so that the powder covers the internal surfaces of the molding. This will cause it to form a layer of uniform thickness. The mold will then be opened and the piece taken out

Settling the Inner Piece 14

In an embodiment, the settling process for the inner piece 14 begins while the piece is still in the machine. The material is permitted to cool in order to allow it to be handled without warping taking place. The machine itself will either blow air on the mold or run water through the mold to facilitate cooling. Once the piece has cooled to a temperature that will allow it to be taken out of the machine without warping (e.g., room temperature), it will be ready for pre-joining.

Settling the Outer Piece 12

In an embodiment, the outer piece 12 is put through a cooling process that is similar to that of the inner piece 14. Once the outer piece 12 reaches room temperature it will be ready for pre-joining.

Pre-Joining the Outer Piece 12 and the Inner Piece 14

According to an embodiment, both pieces are taken from the cooling area and placed into a bin to be taken to the joining stage.

Joining the Outer Piece 12 and the Inner Piece 14

In an embodiment, the pieces will be joined by an extra bit of the material left on the inside piece 14. A pea size piece of epoxy is applied to the inner piece 14 and the inner piece 14 is then pushed into the outer piece 12 and the combined pieces (i.e., the assembled insert 10) is allowed to cool. According to an embodiment, the epoxy is a thermoplastic polymer that chemically transforms into a rigid structure when cooled. When the epoxy has dried the finished part will be transported to the packaging area.

Packaging and Storage

In an embodiment, once an insert has arrived at the packaging area it will be put into a packaging machine. The machine encloses the part in plastic and then an operator will place the part into the shipping box. The shipping box will then be taken into a storage area where it will wait until it is picked up by a shipping company.

The particular implementations shown and described herein are illustrative examples and are not intended to otherwise limit the scope of the disclosure in any way. The steps of all methods described herein are performable in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the disclosure and does not pose a limitation on scope. Numerous modifications and adaptations will be readily apparent to those skilled in this art without departing from the spirit and scope of the disclosure. 

What is claimed is:
 1. A shoe insert configured to receive a foot of a wearer, the shoe insert comprising: an inner piece comprising a plurality of dividers that at least partially separate toes of the foot; and an outer piece covering the inner piece.
 2. The shoe insert of claim 1, wherein the outer piece is folded back onto itself so as to cover the inner piece.
 3. The shoe insert of claim 1, wherein the outer piece is a curvilinear quadrilateral shape.
 4. The shoe insert of claim 1, wherein the outer piece includes a plurality of padded portions, wherein each of the padded portions is thicker than an area of the outer piece surrounding the padded portion.
 5. The shoe insert of claim 4, wherein each of the plurality of padded portions is disposed on a location of the outer piece that corresponds to a respective toe of the wearer.
 6. The shoe insert of claim 1, wherein the outer piece includes a left upper tab that partially covers a lateral left side of the foot and a right upper tab that partially covers a lateral right side of the foot.
 7. The shoe insert of claim 6, wherein the outer piece further includes a left lower tab that partially covers the lateral left side of the foot and a right lower tab that partially covers the lateral right side of the foot, and wherein, when the insert is in use, the left lower tab and right lower tab are located closer to an end of the wearer's foot than the left upper tab and right upper tab.
 8. The shoe insert of claim 1, wherein the outer piece includes an left upper tab that partially covers a lateral left side of the foot and an right upper tab that partially covers a lateral right side of the foot.
 9. The shoe insert of claim 1, wherein the inner piece further comprises a shield, and each of the plurality of dividers extends from the shield.
 10. A shoe insert configured to receive a foot of a wearer, the shoe insert comprising: an inner piece comprising a shield, and a plurality of dividers that at least partially separate toes of the foot; and an outer piece folded back onto itself so as to cover the inner piece, the outer piece comprising a plurality of padded portions, wherein each of the padded portions is thicker than an area of the outer piece surrounding the padded portion and is disposed on a location of the outer piece that corresponds to a respective toe of the wearer, a left upper tab that partially covers a lateral left side of the foot when the insert is in use, a right upper tab that partially covers a lateral right side of the foot when the insert is in use, a left lower tab that partially covers the lateral left side of the foot when the insert is in use, a right lower tab that covers the lateral right side of the foot when the insert is in use, wherein, when the insert is in use, the left lower tab and right lower tab are located closer to an end of the wearer's foot than the left upper tab and right upper tab.
 11. The shoe insert of claim 10, wherein the outer piece is a curvilinear quadrilateral shape. 